Helical pile assembly

ABSTRACT

The present invention generally relates to a helical pile system for use in supporting a support structure used in the oil and gas industry. The helical pile assembly includes a tubular member having a first end and a second end. The helical pile assembly further includes a nose disposed at the first end of the tubular member. The helical pile assembly also includes a first helix disposed on an outer surface of the nose. The helical pile assembly further includes a support member coupled to the tubular member proximate to the second end of the tubular member. The support member is configured to support an external object.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 62/097,708, which was filed on Dec. 30, 2014, and is incorporated herein by reference in its entirety.

BACKGROUND

A helical pile is a screw-in piling used for foundational support. For example, helical piles have been used in the construction industry to support buildings, towers, and other permanent structures. Helical piles are now also being used in the oil and gas industry such as at a refinery, cracker plant sites, and foundation support for pumping units, production equipment, pipelines, related gas distribution systems, and protective structures. The oil and gas industry has different requirements for a foundation support as compared to a typical building construction foundation support. Thus, there is a need for a helical pile assembly that is configured to be used in the oil and gas industry.

SUMMARY

The present invention generally relates to a helical pile system for use in supporting a support structure used in the oil and gas industry. The helical pile assembly includes a tubular member having a first end and a second end. The helical pile assembly further includes a nose disposed at the first end of the tubular member. The helical pile assembly also includes a first helix disposed on an outer surface of the nose. The helical pile assembly further includes a support member coupled to the tubular member proximate to the second end of the tubular member. The support member is configured to support an external object.

In another aspect, a method for manufacturing a helical pile assembly is provided. The method includes the step of providing a tubular member having a first end and a second end. The method further includes the step of positioning a nose on the first end of the tubular member. The nose includes a first helix on an outer surface thereof. Additionally, the method includes the step of securing the nose to the first end of the tubular member.

In yet a further aspect, a method of placing a helical pile assembly into a ground is provided. The method includes the step of advancing a tubular member with a nose into the ground. The nose includes a first helix on an outer surface thereof. The method further includes the step of placing a lateral support device at least partially around the tubular member. The method further includes the step of advancing the lateral support device into the ground after the lateral support device has been placed at least partially around the tubular member. The method also includes the step of coupling a support member to an end of the tubular member opposing the nose. The support member is configured to support an external object.

In an additional aspect, a support device for use with a helical pile is provided. The support device includes a base having a first side and a second side. The support device further includes a coupling configured to engage the helical pile. The coupling is attached to the first side of the base. Additionally, the support device includes a plate configured to support an external object. The plate is attached to the second side of the base using at least one rod member, wherein the plate is movable relative to the base in a vertical direction and a horizontal direction.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present teachings, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present teachings and together with the description, serve to explain the principles of the present teachings. In the figures:

FIG. 1 illustrates a perspective view of a helical pile assembly, according to an embodiment.

FIG. 2 illustrates a side view of the helical pile assembly, according to an embodiment.

FIG. 3 illustrates a cross-sectional view of the helical pile assembly, according to an embodiment.

FIG. 4 illustrates an enlarged view of a top plate and a lateral support device of the helical pile assembly, according to an embodiment.

FIG. 5 illustrates a side view of the top plate of the helical pile assembly, according to an embodiment.

FIG. 6 illustrates a perspective view of a lateral support device of the helical pile assembly, according to an embodiment.

FIG. 7 illustrates a perspective view of a nose of the helical pile assembly, according to an embodiment.

FIG. 8 illustrates a side view of the nose of the helical pile assembly, according to an embodiment.

FIG. 9 illustrates a perspective view of another helical pile assembly, according to an embodiment.

FIG. 10 illustrates a side view of the helical pile assembly shown in FIG. 9, according to an embodiment.

FIG. 11 illustrates a cross-sectional view of the helical pile assembly shown in FIG. 9, according to an embodiment.

FIG. 12 illustrates a perspective view of an underpinning device of the helical pile assembly shown in FIG. 9, according to an embodiment.

FIG. 13 illustrates a front view of the underpinning device of the helical pile assembly shown in FIG. 9, according to an embodiment.

FIG. 14 illustrates a side view of the underpinning device of the helical pile assembly shown in FIG. 9, according to an embodiment.

FIG. 15 illustrates a bottom view of the underpinning device of the helical pile assembly shown in FIG. 9, according to an embodiment.

FIG. 16 illustrates a flowchart of a method for using the helical pile assembly, according to an embodiment.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the present teachings, examples of which are illustrated in the accompanying drawing. In the drawings, like reference numerals have been used throughout to designate identical elements, where convenient. In the following description, reference is made to the accompanying drawing that forms a part thereof, and in which is shown by way of illustration a specific exemplary embodiment in which the present teachings may be practiced. The following description is, therefore, merely exemplary.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all sub-ranges subsumed therein.

FIG. 1 illustrates a perspective view of a helical pile assembly 100, and FIG. 2 illustrates a side view of the helical pile assembly 100, according to an embodiment. The helical pile assembly 100 may include a nose 125, a lead 140 (e.g., a tubular member), and a top plate (also referred to as a support member) 150. The helical pile assembly 100 may also include an optional lateral support device 225 and an optional extension 145 (e.g., another tubular member). The lead 140 and the extension 145 may have a cross-sectional shape that is circular, polygonal (e.g., rectangular), or the like.

The helical pile assembly 100 may be configured to be advanced into the ground by a downward force, a rotational force, or a combination thereof. Thereafter, the helical pile assembly 100 may provide support to an external object, such as pipelines, related gas distribution systems, metal safe room, shelter, or other gas and oilfield equipment and structures. The nose 125 may be configured to reduce the resistance and guide the helical pile assembly 100 as the helical pile assembly 100 is pressed or rotated downward into the ground. The top plate 150 may be configured to support the external object. The lateral support device 225 may be configured to provide lateral support after the helical pile assembly 100 is in the ground.

As shown in FIGS. 1 and 2, the nose 125 includes a nose helix 120, and the lead 140 includes a first helix 130 and optionally a second helix 135. Each helix 120, 130, 135 may be configured to aid in the advancement of the helical pile assembly 100 into the ground. Further, the starting points of the helixes 120, 130, 135 may be rotationally aligned. Additionally, the outer diameters of the helixes 120, 130, 135 may increase along the length of the helical pile assembly 100 from the nose 125 toward the top plate 150. Although three separate helixes 120, 125, 135 are shown in FIG. 1, there may be any number of helixes on the helical pile assembly 100 without departing from the principles of the present disclosure.

FIG. 3 illustrates a cross-sectional view of the helical pile assembly 100, according to an embodiment. As shown, a portion of the nose 125 may be inserted into an end of the lead 140. The nose 125 may be connected to the lead 140 in any suitable manner, such as welding, epoxy, or connection members (e.g., bolts).

The lead 140 and the extension 145 may be connected together using connection members 190, such as bolts. In a similar manner, the top plate 150 may be connected to the extension using connections members 195, such as bolts.

FIG. 4 illustrates an enlarged view of the top plate 150 and the lateral support device 225 of the helical pile assembly 100. As will be discussed herein, the lateral support device 225 may be attached to the extension 145 after the lead 140 and the extension 145 are advanced into the ground. Generally, a base 230 of the lateral support device 225 may be placed around a portion of the extension 145 that is sticking out of the ground. Thereafter, a force may be applied to a plate 235 of the lateral support device 225 which causes blades 245 of the lateral support device 225 to advance the lateral support device 225 toward or into the ground. In the embodiment shown in FIG. 4, the lateral support device 225 may be advanced toward or into the ground independent of the advancement of the lead 140 and the extension 145. In other words, the lead 140 and the extension 145 may be advanced into the ground first and then the lateral support device 225 may be advanced into the ground at a later time.

In an alternative embodiment, the lead 140, the extension 145, and the lateral support device 225 may be advanced into the ground together as a single unit. In this embodiment, a bearing member (not shown) may be placed between the base 230 of the lateral support device 225 and the blades 245 of the lateral support device 225 which allows the base 230 to rotate relative to the blades 245. As such, the blades 245 remain rotationally fixed as the base 230 of the lateral support device 225 is rotated with the lead 140 and the extension 145 during advancement of the helical pile assembly 100 into the ground. In this manner, the lateral support device 225 may be pulled into the ground as the lead 140 and the extension 145 are advanced into the ground.

FIG. 5 illustrates a side view of the top plate 150 of the helical pile assembly 100, according to an embodiment. The top plate 150 may include a body 170, a coupling 165, and a plate assembly 175. The coupling 165 may be configured to engage the extension 145 (see FIG. 4) of the helical pile assembly 100. The coupling 165 may include a bumper plate 185 that abuts an upper end of the extension 145 (see FIG. 4) when the top plate 150 is attached to the extension 145. The configuration of the bumper plate 185 allows the forces applied to the top plate 150 to be transmitted to through the components of the top plate 150 and into the lead 140 and the extension 145.

The plate assembly 175 may be movable relative to the body 170. The plate assembly 175 may include a plate 160 and a stem 155. The stem 155 may be attached directly to the plate 160 via a nut 180 as shown or via welding, epoxy, or the like. In one embodiment, the stem 155 may be a threaded member that is configured to engage internal threads in the body 170. In this embodiment, the plate assembly 175 may be rotated to move the plate assembly 175 relative to the body 170.

FIG. 6 illustrates a perspective view of the lateral support device 225 of the helical pile assembly 100, according to an embodiment. The lateral support device 225 includes the base 230, the plate 235, and the blades 245. The base 230 may include a bore 240 that is configured to slide over a portion of the extension 145. In one embodiment, a bonding agent may be used to connect the lateral support device 225 to the extension 145. The bonding agent may be placed on the extension 145 and/or in the bore 240 of the base 230. The blades 245 are connected to the base 230 and the plate 235. In one embodiment, the blades 245 may have a taper (or chamfer) at the lower end of each blade 245, such as the outer corner, to reduce the resistance and guide the lateral support device 225 into the ground. In another embodiment, the blades 245 may have a saw tooth arrangement at the lower end of each blade 245 to reduce the resistance and guide the lateral support device 225 into the ground. The lateral support device 225 may be configured to provide lateral support device to the helical pile assembly 100.

FIG. 7 illustrates a perspective view of the nose 125 of the helical pile assembly 100, and FIG. 8 illustrates a side view of the nose 125 of the helical pile assembly 100, according to an embodiment. The nose 125 may be disposed at the end of the lead 125. The nose 125 may include a base 110 and a tapered surface 115. The cross-sectional length (e.g., diameter) of the tapered surface 115 may increase moving away from the tip of the nose 125. For example, the tapered surface 115 may be conical or frustoconical. As such, the tapered surface 115 may define an inclination angle. The inclination angle may be characterized as being defined between the tapered surface 115 and a longitudinal centerline through the base 110. The inclination angle may be from about 15 degrees, about 20 degrees, or about 25 degrees to about 35 degrees, about 40 degrees, or about 45 degrees, with respect to the longitudinal centerline of the base 110. This shape may facilitate the nose 125 being used to drill into the ground beneath the lead 125 when the helical pile assembly 100 is advanced into the ground. The nose 125 may be configured to reduce the resistance and guide the helical pile assembly 100 as a downward force pushes the helical pile assembly 100 into the ground.

The nose 125 may also include the helix 120, as shown. In one embodiment, the helix 120 may be a metal bar that is welded to the tapered surface 115. In another embodiment, the nose 125 may be a molded object, and the helix 120 may be molded to the tapered surface 115. The helix 120 may have a start point 205 and an end point 210. The start point 205 of the helix 120 may be aligned with the start point of the helixes 130, 135 on the lead 125. The nose 125 may be made from a metallic material, such as steel. Additionally, the nose 125 and the helix 120 may be made using a forging process, a casting process, a machining process, or a combination thereof.

FIGS. 9-11 illustrate views of another helical pile assembly 300, according to an embodiment. For convenience, the components in the helical pile assembly 300 that are similar to the components in the helical pile assembly 100 are labeled with the same reference characters.

The helical pile assembly 300 may include the nose 125 and the lead 140. The helical pile assembly 300 may also include an underpinning device 325. The helical pile assembly 300 may also include an optional lateral support device (not shown) and the optional extension 145. The nose 125 may be configured to reduce the resistance and guide the helical pile assembly 300 into the ground. The lateral support device (not shown) may be used to provide lateral support after the helical pile assembly 300 is in the ground.

The helical pile assembly 300 may be configured to be advanced into the ground in a similar manner as discussed above. Thereafter, the helical pile assembly 300 may be used to provide support to an external object, such as a concrete or steel structure used in the oil and gas industry. The underpinning device 325 may be configured to support the external object.

FIG. 12 illustrates a perspective view of the underpinning device 325 of the helical pile assembly 300, according to an embodiment. As shown, the underpinning device 325 may include a support 330 that is connected to a base 335 via one or more rods 355. Additionally, the underpinning device 325 may include a coupling member 340 that is configured to couple the underpinning device 325 to the extension 145.

FIG. 13 illustrates a front view of the underpinning device 325 of the helical pile assembly 300. FIG. 14 illustrates a side view of the underpinning device 325. FIG. 15 illustrates a bottom view of the underpinning device 325. After the helical pile assembly 300 is inserted into the ground (and the optional lateral support device is attached), the support 330 may be moved in a vertical direction 315 and/or a horizontal direction 320 relative to the base 335 to allow the support 330 to be positioned adjacent to an external object 305 (shown in FIG. 14). For instance, the plate 330 may be moved in the horizontal direction 320 by adjusting pins 365 in slots 345 (FIG. 15) such that the plate 330 is adjacent to the external object 305 in the horizontal position. Then, the pins 365 may be secured in the location in the slots 345. The plate 330 may be moved in the vertical direction 315 by using a jack 310 (FIG. 13) that is placed between the plate 330 and the base 335. In operation, the jack 310 may be activated to move the plate 330 relative to the base 335 to a vertical position adjacent the external object 305. After the plate 330 is in a proper location, nuts 360 may be moved along the rods 355 (e.g., threaded rod) to a position adjacent the base 335 as shown in FIG. 14. Thereafter, the jack 310 may be deactivated and removed from the underpinning device 325.

FIG. 16 illustrates a flowchart of a method 400 for using the helical pile assembly, according to an embodiment. The method 400 may be employed using one or more embodiments of the helical pile assembly discussed above. However, in other embodiments, the method 400 may be employed to use other helical pile assemblies, and thus may not be limited to any particular structure. The method 400 may begin by advancing the lead 140 with nose 125 into the ground, as at 405. The method may also include adding an extension 145 to the lead 140 if additional depth is necessary for the helical pile assembly, at 410. The lead 140 and the extension 145 may be advanced further into the ground until a predetermined torque value is reached. The method 400 may also include placing the lateral support device 225 around the extension 145, at 415. The lateral support device 225 may be advanced into the ground by applying a vertical/compressive force to the lateral support device 225. The method 400 may further include adjusting the height of top plate 150 (helical pile assembly 100) or the height of the underpinning device 325 (helical pile assembly 300), at 420. Additionally, the horizontal direction of the underpinning device 325 may also be adjusted.

While the present teachings have been illustrated with respect to one or more implementations, alterations and/or modifications may be made to the illustrated examples without departing from the spirit and scope of the appended claims. In addition, while a particular feature of the present teachings may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular function. Furthermore, to the extent that the terms “including,” “includes,” “having,” “has,” “with,” or variants thereof are used in either the detailed description and the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.” Further, in the discussion and claims herein, the term “about” indicates that the value listed may be somewhat altered, as long as the alteration does not result in nonconformance of the process or structure to the illustrated embodiment. Finally, “exemplary” indicates the description is used as an example, rather than implying that it is an ideal.

Other embodiments of the present teachings will be apparent to those skilled in the art from consideration of the specification and practice of the present teachings disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the present teachings being indicated by the following claims. 

What is claimed is:
 1. A helical pile assembly, comprising: a tubular member having a first end and a second end; a nose disposed at the first end of the tubular member; a first helix disposed on an outer surface of the nose; and a support member coupled to the tubular member proximate to the second end of the tubular member, the support member being configured to support an external object.
 2. The helical pile assembly of claim 1, further comprising a second helix disposed on an outer surface of the tubular member between the first helix and the second end of the tubular.
 3. The helical pile assembly of claim 2, wherein a start point of the first helix is aligned with a start point of the second helix.
 4. The helical pile assembly of claim 1, wherein the nose includes a base and a tapered surface, and wherein the first helix extends outward from the tapered surface.
 5. The helical pile assembly of claim 4, wherein the tapered surface defines an inclination angle between 15 degrees and 45 degrees.
 6. The helical pile assembly of claim 1, wherein the support member includes a plate and a base.
 7. The helical pile assembly of claim 6, wherein the plate is adjustable in a vertical direction and a horizontal direction relative to the base.
 8. The helical pile assembly of claim 1, further comprising a lateral support device that is coupled to the tubular member and configured to support the tubular member in a lateral direction.
 9. The helical pile assembly of claim 8, wherein the lateral support device includes a base and a plurality of blades that are circumferentially-offset from one another.
 10. The helical pile assembly of claim 9, wherein each blade of the lateral support device includes a tapered end.
 11. A method for manufacturing a helical pile assembly, the method comprising: providing a tubular member having a first end and a second end; positioning a nose on the first end of the tubular member, the nose having a first helix on an outer surface thereof; and securing the nose to the first end of the tubular member.
 12. The method of claim 11, wherein the tubular member includes a second helix disposed on an outer surface of the tubular member between the first helix and the second end of the tubular.
 13. The method of claim 12, wherein a start point of the first helix is aligned with a start point of the second helix.
 14. The method of claim 11, further comprising attaching a support member to the second end of the tubular member, the support member being configured to support an external object.
 15. A method of placing a helical pile assembly into a ground, comprising: advancing a tubular member with a nose into the ground, the nose having a first helix extending from an outer surface thereof; placing a lateral support device at least partially around the tubular member; advancing the lateral support device into the ground after the lateral support device has been placed at least partially around the tubular member; and coupling a support member to an end of the tubular member opposing the nose, wherein the support member is configured to support an external object.
 16. The method of claim 15, wherein the lateral support device is advanced into the ground independent of the tubular member.
 17. The method of claim 15, further comprising adjusting a vertical position and the horizontal position of the support member relative to the tubular member.
 18. The method of claim 15, wherein a start point of the first helix on the nose is aligned with a start point of a second helix extending from an outer surface of the tubular member.
 19. The method of claim 15, wherein the tubular member is advanced into the ground by applying a rotational force to the tubular member, and the lateral support device is advanced into ground by applying an axial force to the lateral support device.
 20. A support device for use with a helical pile, the support device comprising: a base having a first side and a second side; a coupling configured to engage the helical pile, the coupling being attached to the first side of the base; and a plate configured to support an external object, the plate being attached to the second side of the base using at least one rod member, wherein the plate is movable relative to the base in a vertical direction and a horizontal direction. 